Roofing and process of making the same



L. F. LINDLEY' ROOFING AND PROCESS OF MAKING THE SAME Original, Filed Aprii 12, 192" s 4 M. A. u .w/v. n I/wfl MN flxmfl \N W.

,1 ch'ile Patented Oct. 21, 1930 UNITED STATES LOWELL F. LINDLEY, OF CHICAGO, ILLINOIS Boorme Ann raocnss or MAKING 'rna sum Application filed April 12, 1926, Serial No. 101,232. Renewed larch 8, 1828.

This invention relates to building material commonly called prepared roofing and the process of making the same. Its principal object is to produce such material with form I and character that will, permit its-use in substitution for and imitation of roofing tile.

In the accompanying drawin'gs-- Fig. 1 is a plan view of a portion of .the roof embodying the invention;

Fig. 2 is a side elevation of one of the strips used in making the roof shown in Fig. 1;

Fig. 3 is a diagrammatic side elevation illustrating the process of producing the strip shown in Fig. 2; and Fig. 4 is a sectional view of fragments of the forming rollers.

The roof shown in Fig. 1 is composed of a plurality of strips, or units, each of which includes flat portions 10 and convex or concave ridges 11 between the flat portions. In this preferred form the ridges are circular and join the flat portions so as to make relatively sharp corners 12.

Each strip is composed of a foundation layer of felt 13 impregnated with a. filler stiff at summer sun temperateure, preferabl an asphaltic water proof compound. ver this is a coating of adhesive asphalt 14, and embedded in the asphalt is a layer of grit 15.

The adhesive coating and grit are omitted from one of the marginal fiat portions 10 which is to be covered by the. corresponding marginal portion on the next adjacent strip, thus making joints corresponding with those indicated at 16, Fig. 1.

The strips are nailed to the roof through each of the flat portions where they are covered by the corresponding portions in the next course. In two of the fiat ortions of the strip shown. thenails are con ned to ap-. proximately one-half the width of the strip,.

but-0n the uncoated flat portions additional nails may be added where they will be cov-.

twenty percent (20%), and asphaltum oils rollers will be gradually cooled as the macompound 20, through wringer rolls 21, under a source of grit 22, through wringer rolls 23, through a series of forming rolls 24, 25, 26, under a spray of cold water 27, and finally under a knife 28.

The felt may be of the so-called .rag variety, commonly. used in making prepared roofing, but should he to point, depending upon the stiffness of the impregnating compound and the span of the curved portions 11 of the finished product. The asphaltic impregnating compound best known at the present time consists of gils'onite No. 1, sixty percent (60%); resin, grade G. R. H.,

of 100 penetration, twentypercent (20%).

-These ingredients may be mixed in anysuitable manner, with any suitable apparatus, but the compound should be at about 400 F. when the felt is passed through it.

The adhesive coating of asphalt may be of the composition commonly used in the manufacture of prepared roofing and the grit may be of any desired character, a great variety of which is in common use.

In the process of manufacture theoperations up to and through the rolls 23 wil'lbe of the same character as those performed in--the manufacture of ordinary roofing.

The forming rolls 24, 25 and 26 are pro vided with complementary grooves and ribs 30 and 31 (Fig. 4) for producing the desired profile in the roofing, and this, of course, may be varied to suitindividual preference as to appearance. .1

As a rule three sets of forming rolls, graduated, are necessary to properly form the pro file without injuring the material. The rolls should also be cooled, and in the diagrammatic apparatus this is accomplished b so water-pipes 32 and 33 with the intermediate connections necessary for a continuous flow in series from the rollers 26, through the rollers 24. Thus the successive pairs 'of terial proceeds. After leaving the rollers 26 the cooling spray 27 will practically complete the cooling.

The means 20 and 22 for supplying the adhesive coating and the grit may be readily arranged to skip a marginal area corresponding to one of the fiat portions 10.

The roofing this invention 18 stiff and strong enough to retain its tile-like profile through summer temperature, and when being laid at normal temperatures it will suport the workmen in substantially the same -manner as earthen-' ware tile.

By proper selection of grit the roofing may be given the colors ordinarily found in tile, and thus further simulate the appearance of tile.

It has heretofore been attempted to simulate the appearance of tile in prepared roofing by the use of shades on the surface in connection with ridges and depressions formed in the adhesive coating and grit, as shown for example in patent to McKay, No. 1,208,595 ot December 12, 1916.

It has also been attempted to make felt roofing with corrugations by substituting for the asphaltic impregnating'compounds a chrome-gelatine composition, as described in the patent to Knoch, No. 650,578 of Ootober 30, 1900.

Also it has been pro osed to form the foundation of imitation tile from metal and apply the adhesive coating and grit thereto as shown in patent to Smith, No. 1,513,940 of November 4, 1924:.

The invention here disclosed is easily dis-' tinguishable from those and results in roofing so closely resembling tile roofing in appearance as to escape the detection of the ordinary observer and at the same time affording the advantages of economical manufacture and handling common to prepared roofing in its usual forms.

The roofing is made up in the form of strips, each comprising a plurality of tilelike units. A number of strips piled together bound in a bundle can easily be handled in commerce or upon theroof. In laying, a first course of ordinary rolled roofing may be placed along the lower edge of the root and the first course of tile strips laid with its lower edge adjacent to our projecting from the lower edge of the roof deck. The several strips in a course will be overlapped on the vflat portions and each course will be overlapped by the course above. Generally speaking, strips ten inches Wide, lapped five inches, are to be preferred.

I claim as my invention 1. The process of making prepared roofing which includes impregnating a heavy felt with an asphaltic waterproof compound stifi at summer sun temperature, coating the impregnated felt with alayer of adhesive asrugating the sheet lengthwise into arcuate corrugations and cutting it transversely.

2. he herein described method of making roofing material, which comprises impregroduced in accordance with nating a felt sheet with afluid filler material stid at summer sun temperature, forming a corrugation in the impregnated sheet before the filler material becomes stiff, and permitting the impregnated and corrugated sheet to cool to atmospheric temperature and the filler material to become stiff, whereby the filler material will render the corrugation self-supporting.

3. The herein described method of making corrugated roofing material, which comprises feeding a strip of felt through a bath of filler material which is stifi at summer sun temperature, then continuously forming a corrugation in the impregnated strip longitudinally thereof, then cutting the impregnated and corrugated portion of the strip transversely of the corrugationinto sections, and then permitting the impregnated and corrugated sections to cool to atmospheric temperature, whereby the filler material will render the corrugations self-supporting at summer sun temperature.

4. The herein described method of making corrugated roofing material, which comprises impregnating a felt sheet with a fluid waterproof material that is stifi at summer sun temperature, forming a corrugation in the impregnated sheet before the water-proofing material becomes stiff, and permitting the impregnated and corrugated sheet to cool to atmospheric temperature and the waterproofing material to become stifi, whereby the water-proofing material will render the corrugation self-supporting.

corrugated roofing material, "which comprises feeding a strip of felt through a bath of water-proofing material which is stifi' at summer sun temperature, then continuously forming a corrugation in the impregnated strip longitudinally thereof, then cutting the impregnated and corrugated portion of the strip transversely of the corrugationinto sections, and then permitting the impregnated and corrugated sections to cool to atmospheric temperature, whereby the waterproofing material will render the corrugations self-supporting at summer sun temperature.

6. The herein described method of making roofing material, which comprises continuously feeding a strip of felt through a bath of water-proofing material maintained at about l-OO" Fahrenheit and which is stifi' at summer sun temperature, then continuously feeding the impregnated strip through forming rolls having a pass including a conveXo-concave portion and straight portions I at opposite sides of the conveXo-concave porphalt, embedding grit in said layer, and cortion andlying in one and the same plane, then cutting the impregnated strip transversely into tile sections, and then permitting the sections to cool to atmospheric temperature, whereby the corrugation formed by the gilsonite sixty percent, resin twenty percent.

convexo-concave portion of the pass will be self-supporting at summer sun tern rature.

7. The herein described methodo making roofing material which comprises continuously feeding a strip of felt through a bath of filler material stiff at summer sun temperature, then rolling. longitudinal open-ended and spaced corrugations longitudinally of the impregnated strip, then cutting the strip transversely into sections, and then permitting the sections to cool to atmospheric temperature, whereby the corrugations will be self-supporting at summer sun temperature.

'8. Corrugated felt roofing material impregnated with a filler material still at summer sun temperature, each corru' ationbeing in the form of a hollow open-en ed convexo concavebend extending from one ed e to theopposite edge of the material, an flat flange portions extending longitudinally of the corrugation at oppositesides'thereof and through the length of the corrugation and lying in one and the same plane and constituting the base of the roofing, the filler material rendering the corrugated portion selfsupporting at summer sun temperature.

9. Corrugated felt roofing material impregnated with a filler material stiff at summer sun temperature,yand including about sixty per cent. gilsonite, each corrugation being in the form of a hollow open-ended convexo-concave bendextending from one edge to the opposite edge of the roofing, flat flange portions extending longitudinally 'ofthe corrugation at opposite sides thereof and through the length ofthe corrugation andlying in one and the same plane and constituting the base of the roofing, the filler material rendering the corrugated portion of the tile self-supporting at summer sun temperature.

10. Corrugated felt roofing material impre nated with a, water-proofing material sti at summer sun temperature andincluding gilsonite sixty percent.,'res1n twenty per cent. and asphaltum oils of 100% penetration, twenty percent, each corru ation being in the form of a hollow open-en ed convexoconcave bend extending from one edge to the opposite ed eof the roofing, flat flange portions exten ing longitudinally of the corrugation at opposite sides thereof and throu h the length of the corrugation and lying 1n one and the same plane and constituting the base of the roofing, the filler material rendering the corrugated portion of the tile selfsupporting at summer sun temperature. i

11. The herein described method of making roofing material, which comprises continuously eeding a strip of felt through a bath of waterroofing material maintained at about 400 ahrenheit and which is stiff at summer sun temperature and including and asphaltum oils of 100 penetration twenty per cent., then continuousl feeding the impregnated strip through orming rolls having a pass including a convexo-concave portion and straight portions at opposite sides of the convexo-concave portion and lying in one and the same plane, then cutting the impregnated strip transversely into sections, and then permitting the sections to cool to atmospheric temperature, whereby the corrugation formed by the convexo-concave portion of the pass will'be self-supporting at summer sun temperature.

12. As an article of manufacture, a preparedv corrugated roofing strip comprising a thick strip of felt impregnated with a compound consisting of sixty percent. gilsonite, twenty percent. resin, and twenty percent. heavy asphaltum oils, said impregnating compound being stifi'i-at summer sun temperature and thereby rendering'tlfe cerrugated portion self-supporting.

13. Roofing material comprising a corrugated felt sheet impregnated with a fluid water-proof filler'st1fi"a't summer sun temperature, said filler rendering the corrugated portion still and self-sustaining at summer sun temperature and also stifl' enough at normal temperatures to'support workmen. walkin thereon.

14. oofing material comprising a corruter-prooffiller sti at summer sun temperature and including gilsonite sixty per cent, resin twenty per cent and asphaltum oils of penetration twenty per cent, said filler renderlng the corrugated portion stiff and gated feltsheet imiregnated with a fluidwa 95 self-sustaining at summer sun temperature and also still enoughat normal temperatures to sup ort workmenwalking thereon.

.15. oofing material comprising a corrugated felt sheet impregnated with a fluid water-proof filler stiff at summer sun temperature, each corrugation being in the form of a hollow open-ended convexo-concave bend of arcuate cross-section. extendin from edge to'edge of the sheet, there bem flat flange portlons extending-longitudinal y of the corrugation-at opposite sides thereof and throughout the length of the corrugation, theflanges lying in one and the same plane and constituting the base of the roofing material, said filler. rendering the corrugated portion stiff and self-sustaining at summer sun temperature and also still enough at nor mal temperature to support workmen walking thereon.

16. The continuous .method of making roofing material, which consists in passing a continuous sheet of roofing felt continuously and successively through a filler bath which is stiff at summer sun temperature, then between wringer rolls, thenfto an adhesive coating compound, then throu h" .wringer rolls, then to a discharge of gut,

then between wringer rolls, then through forming rolls having passes shapeoi to produce corrugations longitudinally of the sheet, then to a spray 0i cooling water, and then to means for cutting the sheet trans versely of the corrugations.

In testimony whereof I afiix my signature LOWELL F. LINDLEY. 

